Models, residual design and limits to fault detection for a complex multi-tank hydraulic control system (Q4450430)

The paper presents system modelling, fault detection, and control design issues for a class of serially connected \(n\) subsystems representing a general hydraulic \(n\) tank system. The system is described by a set of nonlinear ODEs with continuous but non-smooth nonlinearities. The case of \(n\) subsystems, where \(n-2\) inner subsystems are inaccessible for measurements, is analysed. Several transformations and input-output maps of the systems are derived to support the control and fault detection objectives for this class of systems. Existence of smooth nonlinearities assures their polynomial approximations. Three smooth state-space models are presented as suitable for observer-based residuals design methods. Equations for an equilibrium operating point are given. Linear and nonlinear static controllers stabilising the system around the required equilibrium are considered. A high-gain nonlinear observer-based residual design and a polynomial model-based design are used to examine residual effectiveness as \(n\) increases. It is shown that the system complexity limits the effectiveness of an observer-based residual. The limit is expressed in terms of a limiting quantity relating measurement error to \(n\).